09 WMI-Policy For Opening Ammonia Refrigeration Systems

POLICY FOR OPENING AMMONIA
REFRIGERATION SYSTEMS (Line Break)

(Section 9)
OVERVIEW (Job Sites)
(1)
This Policy will only be used if the job site customer does not have a
policy, or is less stringent than this policy.
(2)
The policies will be compared with participation from the customer and a
determination of which policy is to be utilized.
DOCUMENTS
APPENDIX 9A
LINE BREAK PERMIT
(Page 10-11)
PURPOSE:
Wagner-Meinert, LLC recognizes that during everyday operations it may become
necessary to shutdown and modify parts of the systems. This policy is intended
to supplement the existing Standard Operating Procedures portion of our
customers Process Safety Management Programs.
The purpose of a policy for opening the ammonia refrigeration system is to
ensure employee safety and to maintain the integrity of the system.
SCOPE:
Under the guidelines of Process Safety Management, Standard Operating
Procedures have been established for individual pieces of equipment and should
be used whenever possible. This policy is in place to provide instructions when
opening of the system is required in locations not covered by the Standard
Operating Procedures.
10/10/2011
09 WMI-Policy for Opening Ammonia Refrigeration Systems.doc
Page 1 of 10
Copyright Wagner-Meinert, LLC
REFERENCES:
A)
Paragraph (j)
Management
OSHA
29
B)
OSHA Instruction CPL 2-2.45A, Process Safety Management of

Highly Hazardous Chemicals-Compliance Guidelines and
Enforcement Procedures
C)
American National Standards Institute/International Institute of

Ammonia Refrigeration. ANSI/IIAR 2-1999, American National
Standard for Equipment, Design, and Installation of Ammonia
Mechanical Refrigeration Systems.
D)
American National Standards Institute/American Society of Heating,

Refrigerating and Air Conditioning Engineers, LLC, ANSI/ASHRAE
15-1994, Safety Code for Mechanical Refrigeration.
E)
American Society of Mechanical Engineers/American National

Standards Institute, ASME/ANSI B31.5-1987, Refrigerant Piping.
F)
IIAR Bulletin R-1, A Guide to Good Practices for the Operation of

an Ammonia Refrigeration System, International institute of
Ammonia refrigeration.
G)
IIAR Bulletin #105, Guidelines for Application and Maintenance of

Safety Pressure Relief Valves for Refrigerant Systems,
International Institute of Ammonia Refrigeration.
H)
IIAR Bulletin #106, Guidelines for Prevention, Preparation,

Response and Cleanup of Ammonia Releases, International
Institute of Ammonia Refrigeration.
I)
IIAR Bulletin #107, Suggested Safety and Operating Procedures

When Making Ammonia Refrigeration Plant Tie-ins.
J)
IIAR Bulletin #109, Minimum Safety Criteria for a Safe Ammonia

Refrigeration System.
K)
IIAR Bulletin #110, Guidelines for Start-up, Inspection and

Maintenance of Ammonia Mechanical Refrigerating Systems.
L)
IIAR Bulletin #111, Guidelines for Ammonia Machinery Room

Ventilation, International Institute of Ammonia Refrigeration.
10/10/2011
CFR
1910.119,
Process
Safety
Page 2 of 10
M)
IIAR Bulletin #116, Guidelines for Avoiding Component Failure in

Industrial Refrigerating Systems Caused By Abnormal Pressure or
Shock, International Institute of Ammonia Refrigeration.
N)
RETA Industrial Refrigeration Course I, II, III, IV, V, VI, VII, and VIII.
P)
Part 1926--Safety And Health Regulations For Construction
DEFINITIONS:
Definitions of regulatory specific terms can be found in S8 Glossary of
Regulatory Terms section of the IIAR Risk Management Guidelines for
Ammonia Refrigeration.
Definitions of refrigeration specific terms can be found in S9 Glossary of
Refrigeration Terms section of the IIAR Risk Management Guidelines for
Ammonia Refrigeration.
PROCEDURES:
Our Policy for opening the ammonia refrigeration system is composed of written
procedures for each of the elements of the program, including:
1.0
2.0
3.0
4.0
5.0
6.0
7.0
PREPARATION FOR REPAIRS

ISOLATION OF THE PIPING SYSTEM TO BE WORKED ON
PUMPOUT OF THE ISOLATED PIPING
OPENING / CUTTING AND WELDING
PRESSURE TESTING
RETURNING ISOLATED PIPING TO SERVICE
FOLLOW-UP
1.0
PREPARATION FOR REPAIRS
1.1
Verify that the change is being done in accordance to the Management of

Change form.
1.2
Verify the delivery of materials and equipment necessary for the cut-in (pipe,
fittings, lifts, cranes, welders, grinders, cutting torches, etc.).
1.2.1 It is essential that piping and fittings conform to the Materials Of
Construction guidelines.
1.2.2 All equipment should be tested to insure safe operation.
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1.2.3 Those individuals making the cut-in, or assisting in the cut-in, should be
familiar with the Operation and Maintenance manuals of the equipment to
be used.
1.3
If Sub-contractors are being utilized, verify that they conform to the requirements
of the Wagner-Meinert, LLC safety policies.
1.3.1 Sub-contractors must be aware of, and adhere to, all Wagner-Meinert,
LLC Safety policies.
1.4
If the system is being opened to install new equipment, the new equipment
should be installed prior to the cut-in, if possible.
1.5
Notify facility personnel of the operation to be performed.

1.5.1 Plant personnel affected by the cut-in should be notified.
1.5.2 Plant personnel should be trained on the dangers associated with
ammonia, including Early Exposure Detection Techniques.
1.5.3 If the system is to be open over several shifts, all affected shifts must be
notified.
1.6
Test all Personnel Protective Equipment (PPE) that may be used during the cutin. All PPE should be tested per manufacturers recommendations.
2.0
ISOLATION OF THE PIPING SYSTEM TO BE WORKED ON

DO NOT ATTEMPT TO ISOLATE ANY PART OF THE PIPING UNTIL THE
ISOLATION POINTS AND ASSOCIATED PIPING HAVE BEEN FIELD
VERIFIED AND THE FOLLOWING PROCEDURES HAVE BEEN COMPLETED.
2.1
Instruct all personnel of isolation procedure.
2.2
Consult the system documentation for isolation points. Field verify all affected
piping.
2.3
Consult the Management of Change form for any specific hazards associated
with the change.
2.4
Put on personnel protective equipment.
2.5
Make sure all safety equipment which may become necessary is available. See
PPE policy for Personal Protective Equipment.
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2.6
Shut off valves to isolate the section of the system you will be working on. DO
NOT ISOLATE SECTIONS OF LIQUID PIPING WITH LIQUID TRAPPED IN
THAT SECTION. THIS CAN CREATE A HYDROSTATIC LOCK, AND CAN
RESULT IN RUPTURED PIPING AND A RELEASE OF AMMONIA! PIPING
RUPTURES MAY INCLUDE FLYING DEBRIS, RELEASES OF OTHER
DANGEROUS CHEMICALS, EXPLOSIONS, ETC.
2.7
Apply Lockout/Tagout per the Lockout/Tagout policy.
3.0
PUMPOUT OF THE ISOLATED PIPING
3.1
Pump out the section of the piping you have just isolated.
3.2
Once the section is pumped out, hold the pumped out section in a vacuum long
enough to verify that the all isolation valves are holding. If Ammonia Liquid is still
present in the piping system you may not be able to hold a vacuum. All Ammonia
should be removed from the piping prior to any cutting operations.
3.3
Dry Nitrogen vapor should be used to purge Ammonia Vapors from the piping.
4.0
OPENING / CUTTING AND WELDING
4.1
Verify that the piping is not under pressure nor in a vacuum. IF PIPING IS IN A
VACUUM, AIR DRAWN IN DURING THE CUTTING PROCESS CAN CREATE
AN EXPLOSIVE MIXTURE. (PURGE WITH NITROGEN)
4.2
Position fans to blow air away from the person welding or cutting.
4.3
Verify that the Hot Work Permits have been issued per the Wagner-Meinert, LLC
Hot Work Permit policy or the customers policy.
4.4
Any concerns or additional precautions outlined in the Hot Work Permit must be
addressed prior to commencement of hot work.
4.5
Make necessary cut-ins. (Before any actual pipe cutting is done, a non-heat
producing tool (drill, hacksaw, port-a-band saw, etc.) to produce a pilot
hole in the top of the pipe to insure the piping is safely evacuated.)
4.6
If the cut-ins are being made to install valves for future service, the downstream
pipe stub of the valves should be capped with gauge valves installed in the caps.
The gauge valve can be used to bleed the section of pipe for future tie-ins.
5.0
PRESSURE TESTING
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Page 5 of 10
5.1
PREPARATION
All joints shall remain non-insulated until field leak testing has been completed.
Prior to testing, the following preparations shall be made:
5.1.1 Valve off and isolate from any test pressures all refrigeration compressors,
liquid pumps, pressure switches, pressure transducers and any other
components that may be damaged.
5.1.2 Remove all safety pressure-relief devices and cap or plug the openings.
This does not include hydrostatic relief valves.
5.1.3 Open all solenoid, pressure regulating, check or other control devices by
means of their manual lifting stems. Check valves or other components
w/o manual opening stems require testing from both directions.
5.1.4 Open all other valves except those leading to the atmosphere. Exclude
valves that are being used to isolate that part of the system.
5.1.5 Cap, plug, or lock shut all valves and devices leading to the atmosphere
per Lockout/Tagout Program.
5.1.6 The test gas shall be introduced into the system through the charging
valve, or other suitable point fitted with a stop valve. The test pressure
shall be verified using a calibrated pressure gauge located on the part of
the system being tested. No leak repairs shall be made while that part of
the system is under pressure. Test pressure is to be witnessed by an
authorized plant person and the testing report is to be signed by that
person.
5.1.7 The system ammonia compressor(s) shall not be used as a source of
pressure for the field leak testing.
5.1.8 A suitable dry gas such as Nitrogen shall be used for field leak testing.
The following fluids shall not be used for field leak testing an ammonia
system:
5.1.8.1
5.1.8.2
5.1.8.3
5.1.8.4
5.1.8.5
5.2
Oxygen or any combustible gas or combustible mixture of

gases
Carbon dioxide
Halocarbon refrigerant
Water or water solutions
Air
LEAK TEST
5.2.1 The High Side and Low Side of the system shall be tested at the greater
of:
5.2.1.1
The relevant field leak testing pressure.
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5.2.1.2
The design working pressure for which that part of the

system has been designed per local and state codes or
industry standard..
5.2.2 Dry nitrogen shall be used to raise the pressure in the ammonia system to
that required for this test with the following provisions:
5.2.2.1
There shall be a suitable regulator located between the

pressure source and the ammonia system, to control the
supply pressure.
5.2.3 Test the section of pipe for leaks. This can be done utilizing leak detection
soap. If leaks exist, remove pressure from pipe, repair leak per
maintenance procedures, then retest pipe.
5.2.4 All discovered leaks shall be repaired, all defective material shall be
replaced and the test process repeated until the system is proven tight
with respect to this test.
5.3
PURGING
5.3.1 The system shall be purged to remove all non-condensable gases which
remain after field leak testing.
6.0
RETURNING ISOLATED PIPING TO SERVICE
6.1
Install insulation as required. All insulation is to be applied prior to refrigerating

the piping.
6.2
Put new branch lines and/or systems into service one at a time.
7.0
6.2.1
Open one branch line / system. This is to prevent overloading the

compressors. Refer to Standard Operating Procedures for specific
instructions as to proper testing and procedures required prior to startup.
6.2.2
Test controls for that branch.
6.2.3
Balance that section.
6.2.4
Slowly lower the temperature in that room (if applicable).
6.2.5
Return to 6.2.1 and put the next branch into service.
6.2.6
Remove Lockout Tags from valves as they are returned to service.
FOLLOW-UP
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Page 7 of 10
7.1
After several hours inspect the area for leaks and abnormalities.
7.2
Finalize Hot Work permits
7.3
Finalize Management of Change form
7.4
Update Equipment lists, Refrigeration drawings, Log Sheets and other system
documentation to incorporate system changes.
DOCUMENT MANAGEMENT:
The Safety Director is responsible for developing and maintaining the program.
If after reading this program, you find that improvements can be made, please contact
the Safety Director. We encourage all suggestions because we are committed to the
success of our written Policy for Opening The Ammonia Refrigeration Systems. We
strive for clear understanding, safe behavior, and involvement from every level of the
company.
CHANGE CONTROL:
All management system changes are reviewed, approved or disapproved by the Safety
Committee.
This program was initially developed on September 19, 2000, replacing the former
Policy for Opening the Ammonia Refrigeration Systems entirely.
Revision No. 1 (September 19, 2000)
Revision or Review No. 2 (January 15, 2001)
Revision or Review No. 5 (September 10, 2003)
Revision or Review No. 9 (September 6, 2007)
Revision or Review No. 10 (March 24, 2010)
Revision or Review No. 11 (October 10, 2011)
PERSONNEL:
The Owners of Wagner-Meinert have the ultimate responsibility for the Policy for
Opening the Ammonia Refrigeration Systems. They have designated the Safety
Director to manage the Policy for Opening the Ammonia Refrigeration Systems.
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LINE BREAK
PERMIT
(APPENDIX 9A)
After determining it is necessary to open critical utility delivery systems, (such as ammonia, steam, air, water or
chemical). This permit must be completed for each line break. This permit is valid for one shift only for
the date of issue and applies only to the work specified below.
Permit Requested By:
Date:
Time:
Location:
Work Performed By:
Work To Be Done:
PERMIT APPROVAL
I CERTIFY THAT ALL CONDITIONS LISTED ON THE REVERSE SIDE OF THIS PERMIT HAVE BEEN
CONFIRMED AND I AUTHORIZE WORK.
Signature:
Authorized Person
POST FINAL INSPECTION
Comments
and any
problems
encountered
I CERTIFY THAT THE JOB SITE WAS REINSPECTED AFTER COMPLETING WORK AND NO LEAKS OR
ABNORMALITIES WERE FOUND. SYSTEM DOCUMENTATION WILL BE COMPLETED TO INCORPORATE
CHANGES AS REQUIRED.
Signature:
Authorized Person
This permit was not designed to apply to all welding and cutting situations. The specific circumstances
of each welding and cutting job should be carefully reviewed and appropriate safety precautions may be
necessary before work begins and while performing work
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Page 9 of 10
POST FINAL INSPECTION

THE WORK AREA MUST NOT BE LEFT UNATTENDED AT ANY TIME WITHOUT SECURING OPEN
ULTILITY DELIVERY SYSTEM.
1. Training of personnel with assigned roles.
All personnel have been trained
Yes
No
All personnel have been informed of potential hazards
Yes
No
Hot Work
Yes
No
Confined Space
Yes
No
3. Line to be opened has been isolated (locked out).
Yes
No
4. All energy sources (stored/potential) have been relieved.
Yes
No
2. Other permits required for this job.
5. Line contains:
6. Test performed (describe):
7. Special hazards:
8. Personal protective equipment required:
9. Other requirements if needed:
10/10/2011
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POLICY FOR OPENING AMMONIA

REFRIGERATION SYSTEMS (Line Break)

LINE BREAK PERMIT

OSHA Instruction CPL 2-2.45A, Process Safety Management of

American National Standards Institute/International Institute of

American National Standards Institute/American Society of Heating,

American Society of Mechanical Engineers/American National

IIAR Bulletin R-1, A Guide to Good Practices for the Operation of

IIAR Bulletin #105, Guidelines for Application and Maintenance of

IIAR Bulletin #106, Guidelines for Prevention, Preparation,

IIAR Bulletin #107, Suggested Safety and Operating Procedures

IIAR Bulletin #109, Minimum Safety Criteria for a Safe Ammonia

IIAR Bulletin #110, Guidelines for Start-up, Inspection and

IIAR Bulletin #111, Guidelines for Ammonia Machinery Room

IIAR Bulletin #116, Guidelines for Avoiding Component Failure in

Part 1926--Safety And Health Regulations For Construction

PREPARATION FOR REPAIRS

PREPARATION FOR REPAIRS

Verify that the change is being done in accordance to the Management of

Notify facility personnel of the operation to be performed.

ISOLATION OF THE PIPING SYSTEM TO BE WORKED ON

Instruct all personnel of isolation procedure.

Put on personnel protective equipment.

Apply Lockout/Tagout per the Lockout/Tagout policy.

PUMPOUT OF THE ISOLATED PIPING

OPENING / CUTTING AND WELDING

Oxygen or any combustible gas or combustible mixture of

The relevant field leak testing pressure.

The design working pressure for which that part of the

There shall be a suitable regulator located between the

RETURNING ISOLATED PIPING TO SERVICE

Install insulation as required. All insulation is to be applied prior to refrigerating

Open one branch line / system. This is to prevent overloading the

Test controls for that branch.

Balance that section.

Slowly lower the temperature in that room (if applicable).

Return to 6.2.1 and put the next branch into service.

Remove Lockout Tags from valves as they are returned to service.

Finalize Hot Work permits

Finalize Management of Change form

POST FINAL INSPECTION

All personnel have been informed of potential hazards

3. Line to be opened has been isolated (locked out).

4. All energy sources (stored/potential) have been relieved.

2. Other permits required for this job.

6. Test performed (describe):

8. Personal protective equipment required:

9. Other requirements if needed:

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